Zanotti Zero Series User manual

Refrigeration excellence since 1962
REFRIGERATION UNIT Series Zero Direct-Drive
INSTALLATION MANUAL
TRANSLATION OF THE ORIGINAL
INSTRUCTIONS

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
2
rev.01
REVISION
The information contained in this manual is the property of ZANOTTI S.p.A.
The drawings and other documents accompanying the refrigeration unit are the property of ZANOTTI
S.p.A.
It is forbidden to distribute and/or duplicate, in any form, this manual, even partially, without the written
authorisation of ZANOTTI S.p.A.
ZANOTTI S.p.A. reserves the right to change, without prior notice, the characteristics of the product
described in this manual.
In case of doubt or difficulty in understanding or interpreting the manual, the original/official version
indicated as "ORIGINAL INSTRUCTIONS" on the cover, must be considered as the valid version.
The contents of this manual have been carefully checked to ensure they correspond to the system in
question.
However, as possible differences cannot be excluded, the contents of this document are periodically
checked and any corrections or modifications will be included in the next edition.
Some of the images included in this manual should only be considered as an example, as they may not
refer to the refrigeration unit described here.
DATE REVISION DESCRIPTION
02/2022 01 First version
06/2022 02 Edit Oil Compressor %

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
3
1GENERAL INFORMATION.......................................................................7
1.1 Introduction .......................................................................................................7
1.2 Symbols ............................................................................................................7
1.3 Manufacturer’s contact details...........................................................................8
1.4 Safety standards ...............................................................................................8
1.5 Manufacturer’s responsibility............................................................................. 8
1.6 Disposal of used materials ................................................................................8
1.7 Refrigeration unit identification ..........................................................................9
1.8 Plant components ...........................................................................................10
1.9 Installation Mode .............................................................................................11
2TECHNICAL DATA.................................................................................12
2.1 Dimensions and mounting measurements ......................................................12
2.1.1 Z200 .....................................................................................................12
2.1.1.1 Nose installation .................................................................................12
2.1.1.2 Roof installation ..................................................................................15
2.1.2 Z250 .....................................................................................................17
2.1.2.1 Nose installation .................................................................................17
2.1.2.2 Roof installation ..................................................................................20
2.1.3 Z350 .....................................................................................................22
2.1.3.1 Nose installation .................................................................................22
2.1.3.2 Roof installation ..................................................................................25
2.1.4 Z380 .....................................................................................................27
2.1.4.1 Nose installation .................................................................................27
2.1.4.2 Roof installation ..................................................................................30
2.1.5 Z380 Multi ............................................................................................32

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
4
rev.01
2.1.5.1 Standard Evaporators .........................................................................32
2.1.5.2 Narrow Evaporators ............................................................................34
2.2 Weights ...........................................................................................................36
3INSTALLATION...................................................................................... 37
3.1 Tools required..................................................................................................37
3.2 Road compressor installation ..........................................................................38
3.3 Unpacking the unit...........................................................................................39
3.4 Removal and mounting of the flaps of the condenser unit...............................41
3.4.1 Removal ...............................................................................................41
3.4.2 Assembly..............................................................................................42
3.5 Lifting the condenser unit ................................................................................43
3.6 Condenser unit installation ..............................................................................45
3.6.1 Nose installation ...................................................................................45
3.6.2 Roof installation ....................................................................................46
3.7 Evaporator installation .....................................................................................47
3.8 Piping connection ............................................................................................48
3.8.1 Connection diagram - single temperature versions ..............................49
3.8.2 Connection diagram - Standard multi temperature versions.................50
3.8.3 Installation of charge junction/gauge connection of road compressor .51
3.8.4 Vacuum pump connection ....................................................................52
3.9 Check for system leaks and vacuum ...............................................................53
3.10 Electrical connections......................................................................................54
3.10.1 Sub-key fuse installation kit ..................................................................56
3.10.2 Discharge heater installation ................................................................57
3.11 Condenser drain hoses installation..................................................................58
3.12 In-cab controller installation.............................................................................59

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
5
3.13 External power supply mode connection socket installation............................ 60
3.14 Loading oil for putting the refrigerator circuit into service ................................61
3.15 Loading the system .........................................................................................62
3.16 Suction pressure regulator valve (CPR)..........................................................63
3.16.1 Adjusting the CPR valve....................................................................... 64
3.17 Expansion valve ..............................................................................................65
3.17.1 Expansion valve adjustment.................................................................65
3.18 Liquid injection valve kit (optional)................................................................... 67
3.18.1 Operating logic .....................................................................................67
3.18.2 Components.........................................................................................67
3.18.3 Installation ............................................................................................67
3.18.4 Injection thermostat..............................................................................68
3.18.5 Cooling diagram with liquid injection valve kit installed ........................69
3.18.6 Wiring diagram with liquid injection valve kit installed ..........................70
3.19 Single temperature heating kit (optional)......................................................... 71
3.19.1 Operating logic .....................................................................................71
3.19.2 Components.........................................................................................71
3.19.3 Installation ............................................................................................71
3.19.4 Wiring diagram with the heating kit installed ........................................72
3.19.5 Cooling diagram with installed heating kit ............................................ 73
3.20 Silencer kit (optional)....................................................................................... 74
3.21 Final checks ....................................................................................................75
4Appendix................................................................................................ 76
4.1 Cooling diagram - single temperature version................................................. 76
4.2 Cooling diagram - multi temperature version...................................................77

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
6
rev.01

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
7
1 GENERAL INFORMATION
1.1 Introduction
NOTE
ZANOTTI S.p.A., the manufacturer of this refrigeration unit in question is referred to in
the manual as Manufacturer.
NOTE
The company that purchased the refrigeration unit is referred to in the manual as
Customer.
This manual contains all the information necessary for correct installation and maintenance of the unit.
1.2 Symbols
The manual uses some symbols which are used to draw the reader’s attention and highlight some
particularly important aspects.
SYMBOL MEANING NOTES
DANGER It indicates a risk of injury to the user. Pay close
attention to the text blocks indicated by this symbol.
CAUTION It is a warning of possible deterioration or damage
to the refrigeration unit. Pay attention to the text
blocks indicated by this symbol.
WARNING
NOTE
It indicates a warning or a note on key functions or
useful information. Pay attention to the text blocks
indicated by this symbol.

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
8
rev.01
1.3 Manufacturer’s contact details
For any type of information or clarification regarding use, etc., the Manufacturer’s Technical Office is
always at the disposal of the Customer’s requests.
The latter should ask questions in clear terms, with references to this manual, always indicating the data
on the identification plate of the refrigeration unit in question.
Any request for intervention, from the Customer's service department, or for clarification regarding the
technical aspects of this document, must be addressed to:
Zanotti S.p.A.
Via M. L. King, 30
46020 Pegognaga (MN) Italy
Phone [phone]
E-mail: [email protected]
1.4 Safety standards
The instructions, indications, standards and related safety notes described in this manual are intended to
define a series of behaviours and obligations to be observed while performing the various installation
activities envisaged on the unit. This is to ensure personnel, equipment, and the environment remain safe.
1.5 Manufacturer’s responsibility
The Manufacturer will not be held responsible for incorrect installation of the unit or for damage caused
by the use of non-authorised components as well as the tampering with circuits, components, and system
software.
It is the manufacturer's responsibility to ensure that the operators (authorised to perform the required
activity) are qualified, adhere to, and are aware of all the requirements of this document as well as the
general safety standards applicable to the unit.
Failure to observe the safety standards can cause injury to personnel and damage to the equipment.
1.6 Disposal of used materials
Packages made of wood, plastic and polystyrene must be disposed of in accordance with the laws in force
in the country where the equipment is used.
Contact your local authority for information on disposal and recycling.

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
9
1.7 Refrigeration unit identification
the model and serial number (or registration number) are shown on the metal plate attached to the side
of the unit (Figure 1) and to the electrical panel (Figure 2).
Figure 1 - Metal plate
Figure 2 - Plate on the electrical panel
1 Model identification 9 Code of wiring diagrams
2 Serial number 10 Low LP pressure (bar)
3 Nominal voltage (V) 11 Low LP temperature (°C)
4 Vehicle absorption (A) 12 Refrigerant type
5 Power consumption (A) 13 Condenser mass (kg)
6 Maximum power consumption (A) 14 HP high pressure (bar)
7 Refrigerant quantity (kg) 15 HP high temperature (°C)
8 Evaporator mass (kg)

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
10
rev.01
1.8 Plant components
The refrigeration unit consists of the following parts (Figure 3):
1. Condenser unit, installed outside the isothermic crate.
2. Evaporative unit installed inside the isothermic crate.
3. Electronic control and command power unit (HMI) , located inside the vehicle cab (in-cab
controller).
Figure 3 - Refrigeration unit Zero Direct-Drive
1 Condenser unit 3 In-cab controller
2 Evaporator

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
11
1.9 Installation Mode
The Zero Direct-Drive refrigeration unit condenser unit can be installed "nose-mounted" (Figure 4), i.e. on
the front wall of the cold room, or "roof-mounted" (Figure 5), i.e. on the upper wall of the cold room
Figure 4- Nose installation
Figure 5 - Roof installation

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
12
rev.01
2 TECHNICAL DATA
2.1 Dimensions and mounting measurements
2.1.1 Z200
2.1.1.1 Nose installation
Dimensions in mm [in].
Figure 6 - Front view of the condenser unit
Figure 7 - Rear view of the condenser unit

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
13
Figure 8 - Side view of the condenser unit + evaporator

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
14
rev.01
Figure 9 - Upper view of the condenser unit + evaporator
Evaporator fastening screws: TE M8x120 (Q.ty 4).

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
15
2.1.1.2 Roof installation
Dimensions in mm [in].
Figure 10 - Front view of the condenser unit
Figure 11 - Side view of the condenser unit + evaporator

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
16
rev.01
Figure 12 - View from the top of the condenser unit
Figure 13 - Top View from the evaporator
Evaporator fastening screws: TE M8x120 (Q.ty 4).

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
17
2.1.2 Z250
2.1.2.1 Nose installation
Dimensions in mm [in].
Figure 14 - Front view of the condenser unit
Figure 15 - Rear view of the condenser unit

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
18
rev.01
Figure 16 - Side view of the condenser unit + evaporator

Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
INSTALLATION MANUAL
rev.01
19
Figure 17 - Upper view of the condenser unit + evaporator
Evaporator fastening screws: TE M8x120 (Q.ty 4).

INSTALLATION MANUAL
Refrigeration unit
Series Zero Direct-Drive
Z200 | Z250 | Z350 | Z380
Z380 Multi
20
rev.01
2.1.2.2 Roof installation
Dimensions in mm [in].
Figure 18 - Front view of the condenser unit
Figure 19 - Side view of the condenser unit + evaporator